How to Measure for a BBQ Cover? | Get the Right Fit the First Time

Measuring a grill for a cover requires three dimensions — width, depth, and height — each taken at the widest point with the lid closed, plus a small margin for ventilation.

Buying a BBQ cover without measuring is a gamble. One wrong measurement leaves exposed metal rusting in the rain or a cover that won’t close over the side burner. Here’s the exact method — grab a flexible tape measure and give yourself five minutes.

Which Three Dimensions Matter?

Every BBQ cover is sized by three measurements: width, depth, and height. Width is the primary sizing metric for US covers and includes fixed side shelves and side burners.

• Width — left to right at the widest point, including fixed side shelves, side burners, outer handles, and rotisserie units.
• Depth — front to back, including front control knobs, the lid handle, rear vents, and any hood overhang.
• Height — from the ground or top of the wheels/casters to the highest point, which is usually the lid handle, chimney cap, or thermometer.

How to Take Each Measurement Correctly

The right technique prevents the common mistakes that cause returns. Keep the grill lid closed the entire time — opening it underestimates the height and gives you the wrong cover.

1. Place the grill in its normal outdoor position with side tables unfolded and the lid shut.
2. Width: Measure from the far-left edge (including the fixed shelf or side burner) to the far-right edge (including the opposite shelf or handle). If shelves fold, measure with them down if the grill goes into storage folded, or up if they stay extended season-round.
3. Depth: Measure from the front-most point (control knobs, lid handle) straight back to the rearmost point (rear vents, lid overhang).
4. Height: Measure from the ground or the top of the casters to the highest point of the closed lid — including any chimney cap, thermometer, or decorative handle spike. Measure at two or three points if the lid shape is uneven, and use the tallest reading.
5. Write down each measurement in inches (US) or centimeters, and add your margin. Round up if you land between sizes.

If the grill has an irregular shape — a rounded back or a protruding thermometer — measure those parts separately and include them in your dimension. The same rule applies for built-in grills: measure the aperture opening and confirm the cover is designed for that specific model.

Common Mistakes That Ruin a Cover Fit

The first-time measurement usually fails for one of these reasons:

• Opening the lid during measurement — you get a shorter height, and the cover doesn’t reach the casters.
• Ignoring fixed side shelves — the cover is too narrow to close over the side burner.
• Skipping the margin — a too-tight cover traps moisture and promotes rust instead of preventing it.
• Measuring from the grill body instead of the ground — you miss the wheel height, and the cover leaves exposed metal.
• Forgetting knobs and handles — the cover won’t pull all the way down over protruding controls.

If the cover drags on the ground, it traps moisture and invites mold. If you’re ready to move from measuring to buying, our roundup of the best-rated BBQ covers lists sizes and fits by grill type.

What to Do After You Measure

Compare your adjusted numbers to the manufacturer’s size range for each cover. If you land between sizes, choose the slightly larger option — a cover that’s a bit loose protects better than one that’s tight. When the cover arrives, test-fit it immediately: it should be snug but not strained, cover the full grill top to bottom, and leave a finger-width of clearance at the bottom for airflow. Match the cover material to your exposure level — waterproof polyester for uncovered patios, lighter UV-resistant fabric for covered decks.